Related Manuals for Air Weigh BinMaxx Cloud
Summary of Contents for Air Weigh BinMaxx Cloud
- Page 1 BinMaxx Cloud Installation Guide For Front End Loaders Air-Weigh Customer Support: 888-459-3247 PN 901-0179-000 R2...
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Page 2: Table Of Contents
Choosing a Location for the Brackets........5 Welding the Deflection Sensor Brackets........6 Installing the Deflection Sensor Extension Cables....8 Placing the Deflection Sensors in the Brackets.......9 Installing the Proximity Bracket and Sensors......10 Welding the Prox Sensor Bracket..........11 Installing the Low and High Prox Sensors......12 Assembling and Installing the Prox Sensor Targets....12 Installing the Prox Sensor Cables..........13 Installing the Cab Electronics............13 Installing the ComLink..............13 Installing to an Existing Wiring Harness........13 Installing the ComLink Wiring Harness......14 Installing the Display..............15 Installing Hardware for BinMaxx Cloud........16 Setting the A/D Values..............17 First Sensor Torque............18 Adjusting the A/D Reading...........19 Final Sensor Torque............20 Adjusting the Proximity Sensors..........20 Adjusting the LO PROX Sensor..........20 Adjusting the HI PROX Sensor..........22... - Page 3 Completing the Installation............24 Finishing Touches...............24 Breaking In the Deflection Sensors.........24 Notes....................25 Limited Warranty................27 Procedure for Warranty Claims...........28...
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Page 4: Binmaxx Cloud Overview
Office contains a laptop and Bluetooth receiver that will be installed at the back office. Only one BinMaxx Cloud Office is needed per business location. Refer to the quick start guide included with BinMaxx Cloud Office for directions on setting up the pre-installed office software and logging into BinMaxx.net. This manual assumes that you are installing BinMaxx Cloud for the first time. If you are replacing an existing BinMaxx with BinMaxx Cloud, please refer to the retrofit insert included with your retrofit kit. -
Page 5: Tools Required
Tools Required • Grinder and medium grit flapper disc • Chalk or permanent marker • Drill and 5/16 inch socket and adapter • Adjustable wrench • 22mm socket and 120 ft. / lb. torque wrench • Spray paint • Welder, MIG or ARC • C-clamps • Tape measure • W ire cutters • Alignment Tool (call Air-Weigh for pricing) Optional Tools • Deflection sensor test box (P/N 1001) , available from Air-Weigh A/D Box (P/N 1001) -
Page 6: Installation Overview
Deflection Sensors (2) Arm Bracket Arm Bracket Bluetooth Mobile DataLink Display Sensor Extension Cables (4) GPS Device LCD Display Cable Proximity Switches ComLink Module Location of BinMaxx Cloud Components Installation Overview There are 3 components of the BinMaxx Cloud scale you will install: • Cab electronic equipment: ComLink, interface cable, display, GPS device, Bluetooth Mobile DataLink and 5dBi antenna • Low and high proximity sensors and cables • Deflection sensors with mounting brackets and cables... - Page 7 White Wire Blue Wire Black Wire In-Line Fuse High-Prox Connector Low-Prox Connector 5800 E Display Two black wires Connector Gray Wire, Brown Wire, Not Used Not Used ComLink Interface Wiring Harness ComLink Connections GPS in Low Prox Sensor J1939 High Prox Power/Ground Left Sensor Right Sensor Printer RS232 Aux Out/Display Sensor (also used for 3rd party integration bluetooth) Antenna GPS Device Bluetooth Mobile DataLink...
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Page 8: Installing The Deflection Sensors
Installing the Deflection Sensors The deflection sensors measure the flex in the lift arms as the truck raises and lowers bins. BinMaxx uses two sensors, one for each arm. Each sensor is mounted to a set of arm brackets on each side of the truck. Choosing a Location for the Brackets • The brackets should be as close to the upper forward curve (closest to the forks of the truck) while remaining level (i.e. not in the curve). • The brackets should not be placed over any hydraulic clamps, couplers or other hardware. (OEM welds may need to be ground down in order to place the BinMaxx arm bracket in the most optimum location.) • The brackets and/or arm sensors cannot be in contact with any other truck component, such as an arm mounted hydraulic line or an arm cable. • The brackets need to be placed in the same position on both arms. Verify positioning on both arms prior to welding the brackets on either side. Ensure that the position chosen does not have any interference on either side. •... -
Page 9: Welding The Deflection Sensor Brackets
Assembling the Bracket and Alignment Tool Jig (# 111-0025) Welding the Deflection Sensor Brackets 1. Assemble the jig installation kit (alignment tool), as shown above. Make sure the bracket halves are pushed flush against the spacer pins in the center of the jig and the space between the brackets is equal and consistent before and after tightening the bolts. 2. Hold the bracket/jig assembly to the underside of the arm over the location you chose for installation earlier. The bottom of the J shaped bracket should face inboard towards the cab to optimize the protection of the arm sensor. Use C-clamps to hold the bracket/jig in place. 3. Using a permanent marker, mark the circumference of the bracket holes on the arm. - Page 10 Tack weld the top, bottom, right and left of each circle. Then the entire circumference. Small Black Circles Indicate Tack-Weld Locations 6. Confirm brackets are flush against arm with no interference from tube clamps, arm welds, etc. 7. Using a MIG or ARC welder, tack-weld inside the two bracket holes (top, bottom, left, and right, as indicated above) and then weld the circumference of the hole. Do not weld in any other location. 8. When the welds are completely cooled, remove the C-clamps. 9. Remove the two bolts from the bracket and jig assembly and remove the jig. Paint the bracket and any bare metal. Avoid getting paint inside of the bracket where it cradles the sensor.
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Page 11: Installing The Deflection Sensor Extension Cables
Installing the Deflection Sensor Extension Cables There are two identical short cables (# 014-1450-113) and two identical long extension cables (# 014-3550-085) used for connecting the deflection sensors to the ComLink in the cab of the truck. Plug one short cable into one long cable and label one set right and one set left before you begin installation. The LEFT sensor cable should be installed on the driver’s side; the RIGHT cable should be installed on the passenger side. 1. Along the existing arm hydraulic lines and wiring, route the short cable (# 014-1450-113) on each side (driver and passenger) from the gap between the arm brackets down the arm. The long cable (# 014-3550-085) plugs into the short cable and then extends to the cab. Make sure to optimize the route to protect the cable. Also ensure that the protective heat shield found on the two short cables is positioned in the locations with the most potential heat exposure. Improper installation could result in damage to the cable. The long sensor cable (approx 35-feet long) will connect to the short cable and be installed in the direction of the cab to be connected to the ComLink. 2. Beginning 12” from the back end of the back arm bracket, attach the sensor extension cable to hydraulic lines along the arm with zip ties every 6” (# 014-1450-113). 3. At the bottom of the arm, route the remaining 35’ extension cable into the cab of the truck along existing truck and body cables. Note: Please ensure that there is a minimum of 12 inches between the wiring and the exhaust piping, or properly shield wiring to protect it from heat. -
Page 12: Placing The Deflection Sensors In The Brackets
4. In the cab of the truck, connect the right-side deflection sensor extension cable to the port labeled “Right Sensor” on the ComLink. (Repeat on the left side.) ComLink will be installed in later step. Deflection Sensor and Bracket Assembly Placing the Deflection Sensors in the Brackets 1. Place each deflection sensor in the bracket, oriented so that the engraved lettering is facing down and so that the pigtail on the sensor is facing toward the front of the truck. 2. Using the washers, nuts, and bolts from the deflection sensor installation kit, secure the deflection sensor to each bracket as shown above. Hand-tighten the bolts (do NOT use tools to... -
Page 13: Installing The Proximity Bracket And Sensors
Installing the Proximity Bracket and Sensors BinMaxx Cloud requires the installation of two proximity sensors, along with their corresponding band clamp targets and bracket. There are a variety of locations where you can successfully install the prox sensor bracket and band clamp targets, depending on your vehicle manufacturer. Possible Configurations for Bracket and Targets... -
Page 14: Welding The Prox Sensor Bracket
Find a location on the body approximately two inches from the arm tube to mount the prox bracket and band clamp targets. The prox sensors will need to face the arm tube where the band clamp targets will be installed. The bracket will bend to fit all body types. 1. Cut, or score and bend, the sensor bracket as short as possible. Excess length can lead to wobbling that will cause the proximity sensor to lose contact with the target plate. After cutting or bending the bracket to the desired configuration, be sure to stabilize the bracket to prevent wobble by welding to the bracket the Air-Weigh provided 1’ steel rod, part number 110-0209-000. This rod can also be cut, if needed. 2. The bracket and band clamp targets should not interfere with any components on the body. 3. There should be enough space to access and tighten the bolts on the band clamp targets. Welding the Prox Sensor Bracket 1. Bend or modify the bracket to fit in the location you have chosen for installation. 2. Using the provided piece of steel, cut and weld the reinforcing gusset. A 12” steel bar has been provided for your convenience. 3. Using a grinder, clear the area where the bracket will be located until nothing remains but Reinforced using bare metal. (provided) steel bar 4. Weld the bracket to the installation location. Installing the Low and High Prox Sensors 1. Place a nut and lock washer on the end of each prox sensor. -
Page 15: Installing The Low And High Prox Sensors
4. Place the second nut and lock washer on each prox sensor and hand tighten. You will adjust them later. Assembling and Installing the Prox Sensor Targets The prox sensor targets attached to the band clamps are used to activate the low and high prox sensors. Note: you will need to perform a final adjustment later in the installation process. 1. Locate the two prox target band clamps and targets. Thread the target onto the band clamp. 2. Place the clamps with the targets on the arm tube and close, but do not tighten. 3. Slide each target and place them so they are directly under the front of the prox sensors. 4. With target centered under the front of each sensor, adjust the prox sensors so they are separated from the targets by 1/8 to 3/16 of an inch. 5. Tighten prox sensor screws so they won’t move. Prox Target Orientation on the Arm Tube Placement of the Targets and Prox Sensors... -
Page 16: Installing The Prox Sensor Cables
Installing the Prox Sensor Cables 1. Locate the two 30-foot prox sensor extension cables. 2. Label the ends of the cables that will be installed in the cab (LO and HI). 3. Connect the appropriate prox cable ends to the cooresponding prox sensor pigtail cables; one for LO and one for HI. 4. Route the cable into the cab (usually through the floor or firewall) to be connected to the ComLink. 5. Connect the low prox cable to the interface jumper wire and then the low prox port on the ComLink. Repeat with the high prox cable and port. (see ComLink Interface Wiring Harness drawing on page 4 for identification). 6. Secure cables with zip ties as necessary. Note: Please ensure that there is a minimum of 12 inches between the wiring and the exhaust piping, or properly shield wiring to protect it from heat. -
Page 17: Installing The Comlink Wiring Harness
Installing the ComLink Wiring Harness The 10-pin ComLink interface wiring harness connects BinMaxx Cloud to the vehicle’s electrical system and the display. See image on next page for a map of the wiring harness and placement of connectors in the ComLink. Follow these steps to install the ComLink interface wiring harness: 1. Connect the white wire to chassis ground, and connect the blue wire to key hot power source (Do not connect directly to ignition switch). 2. Connect the 4-pin connector on the cable labeled “High-Prox Connector” into the corresponding port on the ComLink. The other end of the cable will be attached to the high-prox cable that comes from the proximity sensor. 3. Connect the 4-pin connector on the cable labeled “Low-Prox Connector into the corresponding port on the ComLink. The other end of the cable will be attached to the low-prox cable that comes from the proximity sensor. 4. Connect the 10-pin connector to power port on the ComLink (reads “Power/Ground/Aux Out/Display”). 5. Secure the wiring using zip ties as needed. -
Page 18: Installing The Display
Installing the Display 1. Select a location on the dash where the display can be easily seen and accessed by the driver 2. Before mounting the display, verify that the display cable is long enough to reach from the ComLink to the display 3. If necessary, drill 1/2-inch hole in the dash to run the display cable from the ComLink to the display. If possible, use an already existing hole to run the cable. 4. Clean the surface where you will mount the display using a provided alcohol pad 5. Connect the display cable to the ComLink, then run the cable through the hole to the display and connect it. Press the cable into the routing groove on back of display. 6. If you are not using the mounting pod, remove the adhesive tape backing on the back of the display and adhere the display to the dash using 15 lbs of pressure for 60-seconds. 7. If you are using a mounting pod - • Mount the Pod’s base using the provided double-sided tape, or screw it directly to the dash. Use the provided drill template if you are using screws. • Remove the adhesive tape backing on the back of the display and adhere display to the pod •... -
Page 19: Installing Hardware For Binmaxx Cloud
Installing Hardware for BinMaxx Cloud Note: VHB mounting tape has been included for securing the GPS and Bluetooth devices (pictured on page 4) to the dash. 1. If possible, use the existing hole for the display cable to run the GPS and Bluetooth cables to the ComLink. If necessary, drill additional holes into the dash to allow the Bluetooth and GPS cables to reach the ComLink. Thread the cables through the holes in the dash and connect them to the ComLink. 2. Determine the best location on the dash to secure the GPS device. It should be mounted out of the way of other sensors and in a location that does not obstruct the driver’s view. We recommend installing it on the passenger’s side of the vehicle. 3. Clean the dash where you will mount the GPS device using the provided alcohol pads. -
Page 20: Setting The A/D Values
Setting the A/D Values At this point, you have installed all of the BinMaxx Cloud components. You will next adjust the deflection sensors to read weight correctly by setting their A/D values. Please note that “A/D” refers to the analog-to-digital conversion of the sensor reading. When setting the A/D values, the fork tubes need to be close to the ground, without touching the ground. The forks should be pointing upward, towards the sky. -
Page 21: First Sensor Torque
First Sensor Torque 1. Remove the nuts and add the supplied Threadlocker 242 Loctite© or equivalent to the threads you just exposed and replace. 2. Ensure that the bolt head is in the bolt head holder. The bolt head should be facing toward the truck and the threads should be facing away from the truck. Note: Step 3 can be skipped, if you are using the test box (Air-Weigh optional part number 1001). Turn on the test box and plug arm sensor pigtail into A/D box cable. Deflection sensor A/D readings will be displayed immediately on the screen. -
Page 22: Adjusting The A/D Reading
Adjusting the A/D Reading If the A/D reading is above 1250, follow these instructions 1. Loosen the nuts on both ends of the sensor. 2. At the plastic nut where the cable enters the sensor, exert UPWARD pressure with your finger until the A/D reading is between 750 and 1250, (1000 is an ideal reading). Continue to apply pressure to maintain the desired A/D reading during the torque procedures. 3. Tighten the nut on the NON-CABLE side to 60 ft/lbs first, while maintaining the A/D output at a reading between 750 and 1250 by exerting the proper pressure with your finger on the molded nut at the cable end of the sensor; repeat this process for the nut on the cable side of the sensor. If the A/D readings are still within the 750 to 1250 range after the nuts on both sides of the sensor have been torqued to 60 ft./lbs., continue to instructions for the Final Sensor Torque. If the A/D reading is below 750, follow the steps below 1. Loosen the nuts on both ends of the sensor. -
Page 23: Final Sensor Torque
Final Sensor Torque 1. Tighten both bolts to 120 ft/lbs. 2. Perform a final check of A/D values using the readings from the in-cab BinMaxx Cloud display, not from the AD box. If A/D readings are not within range, repeat the Adjusting the A/D reading steps. Adjusting the Proximity Sensors Desired Fork Heights for Proximity Sensors Adjusting the LO PROX Sensor To accommodate all sizes of bins, the LO PROX switch should be set to turn on when the tallest bin is lifted a few inches off the ground. This is typically about 50” from the ground. 1. Start the truck and wait for the scale to power up. 2. Position the arm torque tube between 48” and 52” from the ground, as close to 50” as possible. - Page 24 3. From the scale display, follow the steps below: • Press ESC to reach the main menu • Use ▲ or ▼ to select DIAGNOSTICS. Press ENTER • Use ▲ or ▼ to select ECU. Press ENTER • Use ▲ or ▼ to select SENSOR DATA. Press ENTER • The A/D readings will display on the BinMaxx Cloud screen. Press ▼ until you see the data that reads PROX SWITCHES along with values. 4. When both the low and high prox sensors are in the off position, the LO PROX and HI PROX values displayed on the BinMaxx Cloud display should be a low number, between 0-5. 5. Rotate the LO PROX sensor target that was installed earlier around the arm torque tube. The LO PROX number on the BinMaxx Cloud display will change from between 0 to 5 to above 1,000 when the sensor is activated. 6. Rotate the target clamp so that the prox sensor is activated at the very edge of the prox sensor. 7. Position the LO PROX target plate so it will remain activated through the lifting zone (approx. 50” - 100” from the ground) and up to the hopper. The switch will turn off on its way back to the ground when the tube is approximately 50” from the ground. Note: If the LO PROX value does not change, check the wiring to make sure all connections are complete and ensure the cables are placed into the proper ports on the ComLink.
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Page 25: Adjusting The Hi Prox Sensor
10. Raise the forks slowly and immediately stop raising once the display changes to a four digit number. 11. Re-measure the tube height to make sure the center of the tube is approximately 48” to 52” from the ground. 12. Repeat Steps 7 to 12 until the fork height is consistently the height identified in Step 2 (48” to 50”) 13. Turn off the truck. Tighten the LO PROX target completely. Adjusting the HI PROX Sensor 1. Start the truck and wait for the scale to power up. 2. Raise the arm torque tube between 98” and 102” from the ground, as close to 100” as possible. 3. From the scale display, follow the steps below: • Press ESC to reach the main menu. • Use ▲ or ▼ to select DIAGNOSTICS. Press ENTER. • Use ▲ or ▼ to select ECU. Press ENTER. • Use ▲ or ▼ to select SENSOR DATA. Press ENTER. • The A/D readings will display on the BinMaxx Cloud screen. Press ▼ until you see the data that reads PROX SWITCHES along with values. 4. When both the low and high prox sensors are in the off position, the LO PROX and HI PROX values displayed on the BinMaxx Cloud scale should be a low number, between 0-5. 5. Rotate the HI PROX sensor target that was installed earlier around the arm tube. The HI PROX number on the BinMaxx Cloud display will change from between 0 to 5 to above 1,000 when the sensor is activated. - Page 26 7. Position the HI PROX target plate so it remains activated above the lifting zone (approx. 50”-100”) on its way to the hopper. The switch will then turn off on its way back to the ground when it hits the lift zone. 8. When the HI PROX sensor target is set in the correct position, tighten the clamp so that it will not slip. 9. Lower the forks a few inches. Follow the instructions in step 3 until you can see the prox sensor values on your BinMaxx Cloud display. The HI PROX display should read between 0 and 5. 10. Raise the forks slowly and immediately stop raising once the display changes to a four digit number. 11. Re-measure the fork height to make sure the forks are approximately 100” from the ground. 12. Repeat Steps 7 to 12 until the fork height is consistently 98” to 102”. (do same for low) 13. Turn off the truck. Tighten the HI PROX target completely.
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Page 27: Completing The Installation
Note: BinMaxx Cloud will display accurate weights only after it has been calibrated. See the calibration procedure on page 2 of the BinMaxx Cloud User Guide included with your scale and also available from Air-Weigh Support or on our website. -
Page 28: Notes
Notes... - Page 29 Notes...
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Page 30: Limited Warranty
Limited Warranty Air-Weigh warrants (the “Limited Warranty”) that the Products will be free from defects in material and workmanship under normal use and service with proper maintenance for the following time periods: (a) for new Scale kits, the Limited Warranty period will be 3 years; (b) for new parts and accessories sold separately, the Limited Warranty period will be 1 year; and (c) for repaired or refurbished items, including repaired or refurbished Scale kits and repaired or refurbished parts and accessories sold separately, the Limited Warranty period will be 90 days. If any Product is determined to not conform to this Limited Warranty during its applicable Limited Warranty period, Air-Weigh will, at its exclusive option, either repair or replace the Product. Limitations of Limited Warranty. Air-Weigh will have no obligation under the Limited Warranty with respect to any product if (a) Buyer fails to notify Air-Weigh in writing during the warranty period of a non-conformity, or (b) Buyer or any other person, entity, or governmental authority uses, misuses, or neglects the product in a manner inconsistent with the product’s specifications or directions for use or maintenance, modifies the product or improperly installs, handles, or maintains the product. No Repair or Modification of the products. Except as explicitly authorized or in a separate written agreement with Air-Weigh, Buyer will not service, repair, modify, alter, replace, reverse engineer, or otherwise change any of the products. Disclaimer of All Other Warranties. EXCEPT FOR THE LIMITED WARRANTIES SET OUT ABOVE, NEITHER AIR-WEIGH NOR ANY PERSON OR ENTITY ON AIR-WEIGH’S BEHALF HAS MADE OR MAKES FOR BUYER’S BENEFIT ANY EXPRESS OR IMPLIED REPRESENTATION OR WARRANTY WHATSOEVER, INCLUDING ANY WARRANTIES OF: (i) MERCHANTABILITY; (ii) FITNESS FOR A PARTICULAR PURPOSE; (iii) TITLE; OR (iv) NON-INFRINGEMENT; WHETHER ARISING BY LAW, COURSE OF DEALING, COURSE OF PERFORMANCE, USAGE OF TRADE OR OTHERWISE, ALL OF WHICH ARE EXPRESSLY DISCLAIMED. BUYER ACKNOWLEDGES THAT IT HAS NOT RELIED ON ANY OTHER REPRESENTATION OR WARRANTY MADE BY AIR-WEIGH, OR ANY OTHER PERSON OR ENTITY ON AIR-WEIGH’S BEHALF. -
Page 31: Procedure For Warranty Claims
Procedure For Warranty Claims ALL customers should first contact Air-Weigh Customer Support Department at (888) 459-3247 for questions regarding the use, operation, repair or return of any Air-Weigh product. In the event Air-Weigh requests to examine the product prior to disposition OR for repair or replacement, Air-Weigh requires a Return Material Authorization (RMA) number be issued before the item is returned. Customer Support will issue the RMA number. Please reference this RMA number in all correspondence. Claimed items shall be shipped freight pre-paid to: Air-Weigh Customer Support Department 1720 Willow Creek Circle, Suite 510 Eugene, Oregon 97402, USA The Air-Weigh RMA number must appear on the outside of the return packaging. Air-Weigh shall examine returned material within 30 days after receipt, or sooner if mutually agreed upon. If Air-Weigh determines that the part or assembly was defective in material or workmanship and within the warranty period, Air-Weigh will repair or replace the part or assembly and return freight pre-paid. In the event Air- Weigh determines that the part or assembly cannot be repaired or replaced and is within the warranty period, a credit not to exceed the purchase price will be issued to the Air-Weigh customer. For our customers using purchase orders Air-Weigh will process a credit memo and notify the customer by email or fax. The customer will process a corresponding debit memo and notify Air-Weigh accordingly. If the part or assembly received by Air-Weigh does not meet the requirements of the warranty program set forth above, at the Air-Weigh customer’s request the part or assembly will either be discarded, returned freight collect, or repaired or replaced at the Air-Weigh customer’s expense and returned freight collect. - Page 32 1730 Willow Creek Circle • Eugene, OR 97402-9152 USA P.O. Box 24308 • Eugene, OR 97402-0437 USA Telephone (541) 343-7884 • Order Desk (888) 459-3444 Customer Support (888) 459-3247 • Fax (541) 431-3121 www.Air-Weigh.com...